19-12 Chapter Nineteen To understand the requirements, one might first look at the configurations and ignore the feature control frames. All four holes are shown centered to the hole in the middle and to the outside of the workpiece. The four holes are dimensioned 23 mm from each other, but since they are depicted centered to the center hole, we must assume each of the four holes is desired to be 11.5 mm from the center hole and from the middle of the workpiece. The hole in the center is exactly that; a hole we desire to be in the middle of the workpiece. The part is then geometrically toleranced in four steps. Step 1, the primary datum feature is identified and given a flatness tolerance. Step 2, the secondary datum feature is identified as one of the 35-mm widths creating a centerplane datum, and the datum feature that generates that centerplane is given a perpendicularity control back to the primary datum plane. Step 3, the tertiary datum feature is identified as the other 35-mm width creating a third datum plane which is also a centerplane datum. The datum feature that generates that centerplane is given a perpendicularity control back to the primary datum plane and the secondary datum centerplane. Step 4 is the simultaneous positional requirement of all five holes to each other and to the primary, secondary, and tertiary datum features. All geometric tolerances of perpendicularity and position are referenced at maximum material condition and use their datum features of size at maximum material condition. This makes it easy to represent each at a constant gage element size, either their MMC or their virtual condition, as applicable. Since in the case of the datum features of size a zero tolerance at MMC has been used, the MMC and the virtual condition are the same. Any gage that simulates these datum features will be able to gage their compliance with their given geometric tolerances and the geometric tolerances of the holes measured from them. The same Functional Gage will also be able to verify compliance with the 35-mm MMC size. Figure 19-8 Position using centerplane datums 19.4.4 Position Using Centerplane Datums Fig. 19-8 shows a simultaneous gaging requirement for a four-hole pattern and a larger center hole. Each uses exactly the same datums in the same order of precedence with the same material condition symbols after the datum features. This creates the simultaneous gaging requirement. This is a very sequential geometric product definition. Receiver Gages — Go Gages and Functional Gages 19-13 Figure 19-9 Gage for verifying four-hole pattern in Fig. 19-8 As shown in Fig. 19-9, step 1 on the gage shown represents datum feature A and gives it a flatness tolerance of 10% of the flatness tolerance on the workpiece. Step 2 on the gage represents datum feature B at a size of 35 mm plus zero and minus 10% of its size tolerance. It is then given exactly the same feature control frame the workpiece has on its datum feature B (10% of zero is still zero). Step 3 on the gage represents datum feature C at a size of 35 mm plus zero and minus 10% of its size tolerance. It is then given the same feature control frame the workpiece has on its datum feature C except it references its datum feature of size B at regardless of feature size. As explained in previous examples, this has the effect of increasing the cost of the gage by decreasing the allowed gage tolerance. However, it has a better chance of producing a gage that will accept more of the produced parts that are within their geometric tolerances. Step 4 on the gage represents all five controlled holes with gage pins. The gage pins begin at the virtual condition of the hole they represent and are toleranced for size with minus zero and plus 10% of the size tolerance of the hole. Then the gage pins are given a position tolerance of 10% of the position tolerance of the hole it represents to the datums simulated in steps 1-3. Again, the datum features of size on the gage are referenced at regardless of feature size, even though the features they simulate are referenced at MMC. Keep in mind this is a personal choice. Gage datum 19-14 Chapter Nineteen feature of size simulations may be referenced at MMC. This will make the gage tolerance larger, and potentially decreases the cost of the gage. It also runs the risk of the gage being made at a size, orienta- tion, and location that rejects more of the technically in-tolerance workpieces it gages. In these examples, a zero tolerance at MMC was used on the controlled datum features of size and therefore a zero tolerance at MMC was used on the gage simulation of the controlled datum features of size. For the purposes of gage tolerancing, one may consider that a workpiece using a geometric tolerance at MMC has a total tolerance that includes the size tolerance and the geometric tolerance. If one adds the size tolerance and the tolerance from the feature control frame on the feature being considered, a true sense of the total tolerance on the feature can be understood. When distributing tolerance on the gage, the tolerance distribution may be that 5%-10% of the total tolerance on the feature being gaged can be used in the size limits of its gaging element, and a zero tolerance at MMC used in its feature control frame. The effect on the gage of this method of tolerance distribution is usually a more cost-effective gage without the possibility that the gage will accept more or less of the parts that it inspects. 19.4.5 Multiple Datum Structures In Fig. 19-10, the positional controls shown use zero at MMC for their geometric tolerances. This makes it easy to illustrate that the only tolerance available for the gage designer to take 5%-10% of is the difference between the MMC and the LMC of the controlled features. In each case, both for the center hole that becomes datum feature D and for the four holes that eventually are positioned to A, D at MMC, and B, a total of 2 mm is used as the size tolerance. This means that when the gage is produced, the gaging elements (pins) that are used to simulate these holes will use a percentage of the 2 mm as the total tolerance on the gage pin sizes and their orientation and location geometric tolerances. This tolerance can be split between the gage pin size and its geometric tolerance or simply used as size tolerance while the geometric tolerance uses zero at MMC, or zero at LMC. Fig.19-10 is sequentially toleranced, with a flatness control given to the primary planar datum feature, a perpendicularity tolerance given to the secondary planar datum feature back to the primary datum, and a perpendicularity tolerance given to the tertiary datum feature back to the primary and secondary datums. Figure 19-10 Multiple datum structures Receiver Gages — Go Gages and Functional Gages 19-15 Figure 19-11 Gage for verifying datum feature D in Fig. 19-10 This completes the first datum reference frame from which the center hole is positioned. The center hole is then made a datum feature (D) from which the outer four holes may be positioned for location on the X and Y axes while using datum A for perpendicularity and datum B for angular orientation. Each geometric control is considered separately verifiable. If gaged, each positional control will be considered a different gage. Since each positional control uses a zero at MMC positional tolerance, the gages that inspect position will also be able to verify compliance with the MMC size envelope. The first gage verifies the position of the center hole. It consists of three planar datum feature simulators, each using exactly the same geometric control as the feature it represents. The only difference is that (as illustrated) a geometric tolerance of 10% of the feature it simulates has been used. The center hole being gaged is represented by a gage pin at the desired basic angle and distance from the datums (as depicted in Fig. 19-11). The gage pin is dimensioned at the virtual condition size of the hole it is gaging and is allowed to grow by 10% (0.2) of the tolerance on the hole. The gage pin is then given a positional tolerance of zero at MMC to the datum features used on the gage. 19-16 Chapter Nineteen Figure 19-12 Gage for verifying four-hole pattern in Fig. 19-10 The last gage for Fig. 19-10 in Fig. 19-12 is used to inspect the position of the four-hole pattern. It begins with a datum feature simulator for datum A and uses a flatness tolerance of 10% of the datum feature it simulates. It also has a datum feature simulator for datum feature B (which is used as a tertiary datum feature to construct a fourth datum plane). This is used to control the pattern rotation (angular orientation) of the four holes and will be a movable wall on two shoulder screws. For the part being gaged to pass the gaging procedure, it will have to make contact with a minimum of two points of high point contact on the datum feature B simulator. This is to assure that the four-hole pattern has met the desired angular relationship to datum plane B and datum feature B. If, for example, only one point was contacted by the part on the datum feature simulator B, it would not assure us that the hole pattern’s orientation had Receiver Gages — Go Gages and Functional Gages 19-17 Figure 19-13 Secondary and tertiary datum features of size been properly maintained to the real surface from which datum B is constructed on the workpiece being gaged. The datum feature simulator for B is given a perpendicularity tolerance back to datum A. The perpendicularity tolerance is 10% of the tolerance on the datum feature it is simulating. Datum feature D is also represented. Again, D is simulated by a gage pin sized to begin at the hole’s virtual condition and then the gage pin is allowed to grow by 10% of the tolerance given to the D hole being represented. The gage pin D is then given a perpendicularity requirement of zero at MMC back to the primary datum. A positional tolerance is not needed for gage pin D as long as enough surface area exists for datum feature A to be properly contacted. The four holes being gaged are then represented with four gage pins of (as required of all gage elements) sufficient height to entirely gage the holes. These gage pins are represented at the virtual condition diameter of the holes they simulate and are allowed a size tolerance of 10% of the tolerance on the size of the holes. This tolerance is all in the plus direction on the gage pin size. The gage pins are then positioned to the datum feature simulators previously described, A primary, D at MMC or RFS secondary, and B tertiary (tertiary datum feature/fourth datum plane used to orient the two planes that cross at the axis of datum D). 19.4.6 Secondary and Tertiary Datum Features of Size In Fig. 19-13, the position of two holes is established by datums A, B, and C (see gage in Fig. 19-14). Once this has been done, the two holes are used as secondary and tertiary datum features (see gage in Fig. 19-15) from 19-18 Chapter Nineteen Figure 19-14 Gage for verifying datum features D and E in Fig. 19-13 which to measure the four 6.1-6.2 holes and the one 10.2-10.4 hole. Since datum feature of size D is used as secondary, it establishes the location of the five holes in both the X and the Y directions. Datum feature of size E is used as an angular orientation datum only. This means that the datum feature simulator on the gage for D is a cylindrical pin made at the virtual condition of the hole it represents (sometimes referred to as a four-way locator). Datum feature E, however, is represented by a width only (sometimes referred to as a two-way locator). Datum feature E is like a cylinder made at the virtual condition of the hole it simulates, but is cut away in the direction that locates it from datum feature D. This is to prevent it from acting as a location datum but rather as only a pattern rotation datum. This use of datum feature simulators in Fig. 19-15 is common. Datum feature simulator E is a tertiary datum feature of size and is represented as an angular orientation datum (a two way locator) with a Receiver Gages — Go Gages and Functional Gages 19-19 diamond shaped (or cut-down cylindrical) pin. However, it is not representative of other types of datum feature simulation. Datum features are normally represented by datum feature simulators that have the same shape as they do; for example planar datum features represented by planar simulators, cylindrical datum features represented by cylindrical simulators, and slot/tab/width datum features represented by datum feature simulators of the same configuration. If datum features D and E had been used as a compound datum (D-E) with both D and E referenced at MMC, D would not have taken precedence over E. Hence, being equal, both would have been used to Figure 19-15 Gage for verifying five holes in Fig. 19-13 19-20 Chapter Nineteen orient and locate the five holes referred to them as though they were a pattern datum consisting of the two holes. In this circumstance, the gage (as shown in Fig. 19-15) would have represented both D and E with cylindrical pins made at the virtual condition of the holes they represent. Both D and E would be consid- ered four-way locators. 19.5 Push Pin vs. Fixed Pin Gaging Although the examples used in this section use fixed pin gages, some thought should go toward the use of push pin gages. With push pin gages, the workpiece is first oriented and located on the gage’s datum feature simulators. Then the gage pins are pushed through holes in the gage and into the holes on the workpiece. This allows the user of the gage to be certain the appropriate type of contact exists between the gage’s datum feature simulators and the datum features on the workpiece being gaged. Push pin gages also provide a better view of which features in a pattern under test are within tolerance and which are out of tolerance. The holes that receive their gage pins are obviously within their geometric tolerance and the holes that are not able to receive their gage pins have violated their geometric tolerance. This information should be helpful to improve the manufacture of subsequent parts. It must be considered that with a push pin – type gage design, gage tolerances are used in a manner that allow the gage pin to easily enter and exit the gage hole with a minimum of airspace. Gage holes that are to receive push pin gage elements should be given geometric tolerances that use a projected tolerance zone that is a minimum height of the maximum depth of the hole being gaged (since the gage hole gives orientation to the gage pin and is likely to exaggerate the orientation error of the gage hole over the height of the gage pin). The gage hole should be treated as though it is a gage pin when calculating its virtual condition. The projected geometric tolerance zone diameter is added to the maximum material condition of the gage push pin diameter to determine the virtual condition of the gage pin when pushed into the gage hole. In Absolute Tolerancing, this gage pin virtual condition boundary may be no smaller than the virtual condition of the hole on the workpiece being gaged. 19.6 Conclusion Receiver gaging provides a level of functional reliability unsurpassed by other measurement methods. Instead of verifying compliance with a theoretical tolerance zone, it transfers that tolerance to the con- trolled feature’s surfaces and creates an understandable physical boundary. This boundary acts as a confinement for the surfaces of the part. It assures one that if the boundary is not violated, the part features will fit into assemblies. ASME Y14.5M-1994 (the Dimensioning and Tolerancing standard) and the ASME Y14.5.1M-1994 (the standard on Mathematical Principles of Dimensioning and Tolerancing) both state that occasionally a conflict occurs between tolerance zone verification and boundary verifica- tion. They also state that in these instances, the boundary method is used for final acceptance or rejec- tion. 19.7 References 1. American National Standards Committee B4. 1981. ANSI B4.4M-1981, Inspection of Workpieces. New York, New York: The American Society of Mechanical Engineers. 2. Meadows, James D. 1995. Geometric Dimensioning and Tolerancing. New York, New York: Marcel Dekker. 3. Meadows, James D. 1998. Measurement of Geometric Tolerances in Manufacturing. New York, New York: Marcel Dekker. 4. Meadows, James D. 1997. Geometric Dimensioning and Tolerancing Workbook and Answerbook. New York, New York: Marcel Dekker. 5. The American Society of Mechanical Engineers. 1995. ASME Y14.5M-1994, Dimensioning and Tolerancing. New York, New York: The American Society of Mechanical Engineers. [...]... Gregory A Hetland, Ph.D Hutchinson Technology Inc Hutchinson, Minnesota Dr Hetland is the manager of corporate standards and measurement sciences at Hutchinson Technology Inc With more than 25 years of industrial experience, he is actively involved with national, international, and industrial standards research and development efforts in the areas of global tolerancing of mechanical parts and supporting... material of the part, and the capability required 20.2.2.5 Fixturing Sources of Uncertainty Part fixturing is listed separately because part distortion within the holding fixture is one of the error sources involved Other concerns involve the dynamic properties of the fixture’s material, but this depends on the application For example, given a situation where the temperature is unstable and the part is fixtured... unnecessary testing and should focus any diagnostic testing that may be required 20.2 .3 Measurement System Qualification (Phase 3) 20.2 .3. 1 Plan the Capabilities Studies There are many published standards discussing the evaluation of CMM performance The same is true for other equipment as well These standards are particularly effective because they pertain to testing the machine for performing within... Correlation (internal and external) Many tools exist for testing, and shorter versions of those tests may be useful in evaluating the sensitivity of specific error sources Such testing is often referred to as “snapshot testing.” While not valid for formal analysis, snapshot testing provides sufficient insight into machine performance, particularly for a new and unknown system 20.2 .3. 3 Calibrate the System... a machine scale Generally though, the workpiece and scale expand by different amounts This is termed “differential expansion.” With no other problem, error equals workpiece expansion minus scale expansion over the length of the measurement Expansion Uncertainty Coefficients of expansion are given in shop, engineering, or scientific handbooks Different handbooks will in some cases state different coefficients... performance in reproducibility, between machines, and between operators The sensitivity of fixturing factors is highly dependent on environmental conditions, part and fixturing materials, and the measurement system capability required 20.2.2.6 Operator Sources of Uncertainty The user of the system can greatly influence the performance of any measurement system This is particularly true within the lab environment,... strategies, and even the location and orientation of the part can affect the uncertainty of measurements For this reason, laboratory personnel must be required to maintain a higher level of competency Formal, documented procedures should be available for reference The sensitivity of these concerns is highly dependent on the competency of the personnel involved, the release and control procedures for part. .. the sources of error to the machine’s and the part s properties within those conditions 20.2.2.4 Part Sources of Uncertainty Many aspects of the parts themselves can be a source of measurement uncertainty The dynamic properties, such as geometric distortion due to probing force or vibration, are obvious examples Likewise, the coefficient of thermal expansion of the parts’ material should be considered... final capability matrix should address all concerns relative to the capability desired Once the capability and its availability are known, the cost and budget analyses and timelines are required Such analysis is extremely difficult and must include considerations such as personnel requirements and maintenance costs 20.2.2 Identification of Sources of Uncertainty (Phase 2) This step involves identifying... The calibration lab should provide support through consulting and services The services must include automated monitoring of the calibration cycle and maintaining historical records of the calibrations performed 20-8 Chapter Twenty 20.2 .3. 4 Conduct Studies and Define Capabilities The requirements of this step involve the data collection and documentation processes If the studies are well planned, conducting . assemblies. ASME Y14.5M-1994 (the Dimensioning and Tolerancing standard) and the ASME Y14.5.1M-1994 (the standard on Mathematical Principles of Dimensioning and Tolerancing) both state that occasionally. interna- tional, and industrial standards research and development efforts in the areas of global tolerancing of mechanical parts and supporting metrology. Dr. Hetland’s research has focused on tolerancing. Geometric Dimensioning and Tolerancing Workbook and Answerbook. New York, New York: Marcel Dekker. 5. The American Society of Mechanical Engineers. 1995. ASME Y14.5M-1994, Dimensioning and Tolerancing. New